Modular system for building structures

ABSTRACT

A modular assembly of a plurality of elongate modules with a uniform cross-section and at least one adjacent module engagement surface with an elongate groove extending the length of the module. Adjacent modules of the assembly are laterally linked together with their engagement surfaces abutting each other and connectors mounted in the grooves of each adjacent module spanning therebetween.

TECHNICAL FIELD

[0001] The invention relates to a modular system for construction ofbuilding structures such as walls, floors or concrete forms includingmodular panels and releasable interlocking keys.

BACKGROUND OF THE ART

[0002] In general, the invention relates to a modular assembly systemfor making concrete forms or other building wall structures, of atemporary or permanent nature. The basic component is a rectangularshaped body module formed from an aluminium extrusion cut in variousstandard lengths such as 4 feet, 8 feet, 12 feet, etc. A standard modulemay have a 12 inch width for example and be 3½ inches thick althoughother sizes and shapes can be easily provided by manufacturing extrusiondies accordingly. The module includes cylindrical grooves along itslength which allow for interlocking between adjacent modules using aninternally mounted figure-8 shaped key or externally mounted bracketwith a wedge connector. The key and/or bracket connectors can join panelmodules lengthwise and laterally. Other connectors and accessories maybe provided for assembling various structures as described in detailherein.

[0003] The present invention relates to an innovative system,particularly useful in today's building industry, in that provides acompetitive edge in the market place in all the aspects of:

[0004] construction materials (for structural and architecturalapplications)

[0005] products (for conventional and reinforced concreteprojects/applications)

[0006] systems (for below-grade, above-grade, exterior, or interiorapplications)

[0007] services (mostly related but not limited to thesingle-family-housing/building industry)

[0008] The present invention implies the use of a novel forming system,which is primarily intended to simplify and encourage the use of theconcrete for all, and combination of:

[0009] Site installed, as part of a generic building system,applications

[0010] Site assembled, as a proprietary building system, applications

[0011] Site manufactured where minimum semi-skilled labour and standardconstruction methods are used.

[0012] In the prior art, concrete poured works have been provided withlimited sizes and ranges of forming panels, requiring extensive use ofaccessories for build ups and still of limited uses.

[0013] These earlier methods have the drawback that they cannot accountfor different construction variables without the burden of extensivefield modifications. Moreover handling and erection of these earlierpanels work is laborious and time consuming.

[0014] Further advantages of the invention will be apparent from reviewof the disclosure, drawings and description of the invention below.

DISCLOSURE OF THE INVENTION

[0015] The invention provides a modular assembly of a plurality ofelongate modules with a uniform cross-section and at least one adjacentmodule engagement surface with an elongate groove extending the lengthof the module. Adjacent modules of the assembly are laterally linkedtogether with their engagement surfaces abutting each other andconnectors mounted in the grooves of each adjacent module spanningtherebetween.

[0016] The modular assembly may comprise a composite panel system ofextruded aluminium work. A forming building system wherein said concreteforming system is a re-usable, versatile, lightweight aluminum modularsystem for concrete work applications.

[0017] According to the present invention, there is a forming systemcomprising an exclusive combination of precision extruded unitsmodularly connected by extruded key-joints and bracket connectors for anextensive variety of modifiable and re-usable applications of concreteforming work.

[0018] An important advantage afforded by the unique forming system ofthe present invention is that it can be employed for walls, floors androofs on load bearing or non-load bearing applications with severalinherent benefits further detailed herewith.

DESCRIPTION OF THE DRAWINGS

[0019] In order that the invention may be readily understood,embodiments of the invention are illustrated by way of example in theaccompanying drawings.

[0020]FIG. 1 shows a cross-sectional view through an elongate module orextruded aluminium panel of generally rectangular shape having foursides with a cylindrical groove together with a filler strip for thegroove, a figure-8 shaped connector and a reveal module.

[0021]FIG. 2 is a like cross-sectional view showing the method ofinterconnecting two adjacent modules with the “figure-8 shaped”connector slidably engaged in adjacent grooves.

[0022]FIG. 3 is a plan view of a wall assembled of four elongate modulesconnected together.

[0023]FIG. 4 is a sectional view of the wall assembly shown in FIG. 3.

[0024]FIGS. 5, 6 and 7 are cross-sectional views showing variousarrangements of two modules joint together to form a corner using asingle figure-8 connector.

[0025]FIGS. 8 and 9 are cross-sectional views showing two identicalmodule joint together with a connector and an angular offset module.

[0026]FIG. 10 is an arrangement showing the formation of the cornerusing interconnecting modules.

[0027]FIGS. 11 and 12 are cross-sections showing a method orinterconnecting modules to form a wall having ribs on one side and ontwo sides respectively.

[0028]FIGS. 13 and 14 show methods of connecting the modules to formwalls of various thicknesses and configuration.

[0029]FIGS. 15, 16, 17 and 18 show method of using the modules to formconcrete columns of varying cross-sectional configuration.

[0030]FIG. 20 shows use of the modules to form a concrete form to pour aribbed wall.

[0031]FIG. 21 shows an elevation view of a concrete form created to forma wall with windows, door and foundation.

[0032]FIG. 22 is a cross-sectional view through the form of FIG. 21showing the footing and wall sections.

[0033]FIG. 23 is a detailed view of the form work to create a footingwith wall for a building.

[0034]FIG. 24 is an exploded view of the form work shown in FIG. 23.

[0035]FIG. 25 is an alternative method of connecting the modulestogether using external brackets mounted in the outwardly facing groovestogether with a wedge inserted in a slot within the brackets to formplanar wall portions and corners.

[0036]FIG. 26 shows combination of the figure-8 connector and thebrackets with wedge inserted in the slot.

[0037]FIG. 27 shows the corner module and exploded view with wedge andslot locking mechanism.

[0038]FIG. 29 is a perspective view of a single module with end caps ateach end, and six holes drilled through side walls to conduct fluidthrough the module for heating or cooling.

[0039] Further details of the invention and its advantages will beapparent from the detailed description included below.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0040]FIGS. 1 through 4 illustrate basic components of the modularassembly, which in the case of FIG. 3 has been assembled in a simpleplanar wall arrangement of four identical modules 1. As best seen inFIG. 1 each elongate module 1 has a length L (shown in FIG. 3) and auniform generally rectangular cross-section. In order to interconnectwith adjacent modules 1, each module 1 has at least one engagementsurface 2 and at least one elongate groove 3 extending the length L ofthe module 1.

[0041] As shown in FIG. 2, adjacent modules 1 of the assembly arelaterally linked together with their engagement surfaces 2 abutting eachother. In the embodiment shown in FIGS. 1 through 4, a figure-8 shapedconnector 4 is mounted in the groove 3 of each adjacent module 1 andexpands between the modules 1. FIGS. 3 and 4 show a simple rectangularwall assembled of four identical modules 1 joined together with threefigure-8 connectors 4 mounted in the grooves 3 of each adjacent module1.

[0042]FIG. 1 also shows a solid groove filler strip 5 which is ofcomplimentary shape to the groove 3 and fills in the space in thegrooves 3 when the modules 1 are used to form concrete for example sothate the filler 5 prevents inflow of liquid concrete. FIG. 1 also showsa reveal module 6 which may be mounted to the primary module 1 invarious locations to create architecturally interesting grooves or ribsas desired in a finished concrete surface.

[0043] In the embodiment shown in FIG. 1 the module 1 is adapted formanufacture in an aluminium extrusion process. The grooves 3 aredisposed in the engagement surfaces 2 however it will understood thatgrooves 3 and engagement surfaces 3 can be separated if desired and neednot be in the same vicinity. The figure-8 connector 4 has two ends 7each adapted for sliding engagement within the grooves 3.

[0044] In the embodiment shown in FIGS. 25 through 27, the connectorsmay comprise a bracket 8 having a first end 9 that is adapt for slidingengagement in the groove 3 and a second end 10 having a slot opening 11.A wedge 12 is slidably engaged in the slot 11 of cooperating brackets 8in order to secure adjacent modules 1 together. Also, in the embodimentshown in FIGS. 25 and 27, the groove filler strip 5 may comprise a thinwalled strip as opposed to a solid strip that fills the entire groove 3.

[0045] The embodiment shown in FIG. 1 includes grooves 3 which aresubstantially cylindrical in internal surface and engagement surfaces 2which are substantially planar. The module 1 illustrated has arectangular cross-section and planar engagement surfaces 2 with grooves3 in all four sides of the rectangular cross-section. However, any shapeof cross-section with any number of engagement surfaces and grooves maybe provided depending on the requirements of the specific application.For ease of understanding and in view of the general use of rectangularforms for building materials a rectangular shaped cross section has beenadopted in this description and drawings. When used for concreteformwork, scaffolding, platforms or stages, stairs or temporarilybuilding structures, a simple rectangular shape is often desirable andis easily adapted as a replacement for wood. For example, asubstantially planar low bearing surface 13 can be used to containconcrete or provide a platform surface in various structures.Alternatively, the opposite load bearing surface 14 is provided with atrapezoidal cross section channel 15 which can be used to form ribs informed concrete floors or floor surfaces as explained in detail below.

[0046] Further, in the embodiments shown in FIGS. 8 and 9, modules 1 canbe connected together with an elongated figure-8 connector 4 togetherwith an angular offset module 16 having two engagement surfaces that aredisposed at an angle ‘α’ relative to each other.

[0047]FIGS. 5, 6 and 7 show two modules 1 connected together with afigure-8 connector 4 in various different configurations to provide flatsurfaces or ribbed surfaces on inside and outside corners of a concreteform for example.

[0048] Likewise, FIGS. 10, 11, 12, 13 and 14 show various configurationsof concrete forms to create corners, ribs and different wall thicknessfor concrete form work utilizing identical modules 1 and connectors inaccordance with the invention.

[0049]FIGS. 15, 16, 17 and 18 also illustrate various configurations ofidentical modules 1 with connectors to form columns of poured concretein various shapes and cross-sectional areas. The modularity of the formwork provides the advantage that various shapes and sizes can be createdusing identical re-useable modular components.

[0050]FIG. 20 shows an exploded view of formwork removed from thefinished work showing the means by which a completely planar concretewall surface and alternatively an opposite ridged wall surface can beformed. It will be understood by those skilled in the art that floorsurfaces wall and other structural components may be formed in a likemanner with or without ridges and with various thicknesses as desired.

[0051]FIGS. 21 and 22 show use of the modules 1 to pour the concretewall of the building for example with a door opening 17 and windowopening 18. The bottom portion of the form may have a footing portion oflarger width.

[0052]FIGS. 23 and 24 show the example of forming the wall of concretehaving a footing 19 where modules 1 are used to form a footing 19 aswell as a wall portion 20. Angle iron brackets 21 supporting sections ofmodules 1 of various lengths can be adapted to form wall 20 and footings19 of various shapes and configurations.

[0053]FIG. 29 is a perspective view of a single module 1 with end caps22 at each end, and six holes 23 drilled through side walls to conductfluid through threaded fittings 24 and hoses 25 for heating or coolingthe module 1. When the modules 1 are used to construct concrete formworkfor example, heating of concrete in the winter or cooling during summercan be carried out by circulating hot or cold liquid with pumps throughthe hoses 25 and chambers created in the module 1 between end caps 22.The same arrangement may be used to inject liquid foam that later curesfor insulating or structural reinforcing functions.

[0054] Although the above description relates to a specific preferredembodiment as presently contemplated by the inventor, it will beunderstood that the invention in its broad aspect includes mechanicaland functional equivalents of the elements described herein.

We claim:
 1. A modular assembly comprising: a plurality of elongatemodules having a length, each having: a uniform cross-section; at leastone adjacent module engagement surface; and an elongate groove extendingthe length of the module; wherein adjacent modules of the assembly arelaterally linked together with the at least one engagement surface ofeach module abutting an adjacent module; and a plurality of connectorsmounted in the grooves of each adjacent module and spanningtherebetween.
 2. A modular assembly according to claim 1 wherein thegroove is disposed within the engagement surface.
 3. A modular assemblyaccording to claim 1 wherein the connector has two ends each adapted forsliding engagement with said groove.
 4. A modular assembly according toclaim 1 wherein the connector comprises a brackets each with a first endadapted for sliding engagement with said groove and a second end havingan opening.
 5. A modular assembly according to claim 4 wherein theopening comprises a slot and the connector further comprises a wedgeslidably engagable in said slot.
 6. A modular assembly according toclaim 1 wherein the groove has a substantially cylindrical internalsurface.
 7. A modular assembly according to claim 1 wherein theengagement surfaces are substantially planar.
 8. A modular assemblyaccording to claim 1 wherein the module has a planar load bearingsurface.
 9. A modular assembly according to claim 1 wherein the modulehas a load bearing surface with an elongate channel.
 10. A modularassembly according to claim 9 wherein the elongate channel has atrapezoidal cross-section.
 11. A modular assembly according to claim 1wherein the module has a rectangular cross-section.
 12. A modularassembly according to claim 11 wherein the module has engagementsurfaces with grooves on four sides of the rectangular cross-section.13. A modular assembly according to claim 1 comprising a groove fillerstrip.
 14. A modular assembly according to claim 1 comprising an angularoffset module having two engagement surfaces disposed at an anglerelative to each other.
 15. A modular assembly according to claim 1comprising a reveal module.
 16. A modular assembly according to claim 1wherein the module has at least one internal chamber defined between atleast two end caps, each chamber having a fluid inlet and a fluidoutlet.